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Reducing The Uncertainty In The Prototyping Process

Reducing The Uncertainty In The Prototyping Process. A Review of Rapid Prototyping Selection Systems. Kevin Steele Rapid Design and Manufacture Centre. Concept Evaluation Techniques. Empathy. Inversion. DFMA Guidelines. Competition Analysis Techniques. CAD. SPC. TIME. Introduction.

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Reducing The Uncertainty In The Prototyping Process

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  1. Reducing The Uncertainty In The Prototyping Process A Review of Rapid Prototyping Selection Systems Kevin Steele Rapid Design and Manufacture Centre

  2. Concept Evaluation Techniques Empathy Inversion DFMA Guidelines Competition Analysis Techniques CAD SPC TIME Introduction Market Need Specification Conceptual Design Concept Evaluation Detail Design Manufacture PROTOTYPING TECHNIQUES

  3. Market Need Specification Conceptual Design Concept Models Concept Evaluation Detail Design “Fit and Form” Models Rapid Tooling Manufacture Overall Aim • Save Time • Reduce Costs TIME

  4. Commercial Contexts Internal Prejudices Company Restrictions Business Aspects TIME

  5. VIRTUAL MANUAL RENDERING 3D CAD VR Prototyping Options PROTOTYPING TECHNIQUES NONE PHYSICAL L.M MANUAL CNC • L.M = Layered Manufacture (RP/T)

  6. Issues within Layered Manufacture • Rapidly Growing number of Technologies • Growing Number of Interactions • 25 + RP Technologies : 19 + RT Technologies • Escalating Number of Materials • Growing User Base • Exponential rise in the number of RP systems in existence

  7. RAPID PROTOTYPING SLA SLS LOM FDM SANDERS CNC DMLS CONCEPT MODELLING 3DP ThermoJet Objet Genesys Prodigy JP5 Modelling Technologies Materials ZP11/14 Powder RapidSteel CastForm SLA Resins LOM Papers Wax ABS Inv. Casting Vacuum Casting Keltool Metal Filled Epoxy Tooling Post Processes Spray Metal Tooling Sand Casting The Process Chain Concept REQUIREMENTS DEFINITION (RP&T) Wax Infiltration

  8. Case Study 1: McAlpine Plumbing • Requirements: Must exhibit waterproof properties • Process Chain Used: FDM with a wax infiltrant

  9. RAPID PROTOTYPING SLA SLS LOM FDM SANDERS CNC DMLS CONCEPT MODELLING 3DP ThermoJet Objet Genesys Prodigy JP5 Modelling Technologies Materials ZP11/14 Powder RapidSteel CastForm SLA Resins LOM Papers Wax ABS Process Chain Used: McAlpines REQUIREMENTS DEFINITION (RP&T) Inv. Casting Vacuum Casting Keltool Metal Filled Epoxy Tooling Post Processes Wax Infiltration Spray Metal Tooling Sand Casting

  10. Case Study 2: Tronic • Rubber seal for protecting sub-sea connector • Process Chain: ZP11 Powder combined with elastomer infiltrant

  11. RAPID PROTOTYPING SLA SLS LOM FDM SANDERS CNC DMLS CONCEPT MODELLING 3DP ThermoJet Objet Genesys Prodigy JP5 Modelling Technologies Materials ZP11/14 Powder RapidSteel CastForm SLA Resins LOM Papers Wax ABS Process Chain Used: Tronic REQUIREMENTS DEFINITION (RP&T) Inv. Casting Vacuum Casting Keltool Metal Filled Epoxy Tooling Post Processes Wax Infiltration Spray Metal Tooling Sand Casting Elastomer Infiltration

  12. Case Study 3: Galtronics • Mobile Phone antenna frame • ZP100 & Cyanoacrylate Resin: Unsuitable • Correct Process Chain: FDM

  13. RAPID PROTOTYPING SLA SLS LOM FDM SANDERS CNC DMLS CONCEPT MODELLING 3DP ThermoJet Objet Genesys Prodigy JP5 Modelling Technologies Materials ZP11/14 Powder RapidSteel CastForm SLA Resins LOM Papers Wax ABS Process Chain Used: Galtronics REQUIREMENTS DEFINITION (RP&T) Inv. Casting Vacuum Casting Keltool Metal Filled Epoxy Tooling Post Processes Wax Infiltration Spray Metal Tooling Sand Casting Elastomer Infiltration

  14. Case Study 4: Agilent • Only Company with in-house RP • User of 3DP, SLA, and SLS • Company Procedures get in the way of RP Adoption

  15. Case Studies - Conclusions • Important to establish prototype requirements before embarking on RP • Knowledge of Process Capability imperative • Vital to have understanding of process relationships between RP, RT and Materials • Business Considerations can serve as an obstacle to successful RP implementation

  16. Previous Approaches 1 • Simple RP Selection Expert Systems • Lack depth of information, no Process Chain capability

  17. Previous Approaches 2 • Process Chain Selectors • RAPTEC, PROTOOL • Select complete process chains

  18. Previous Approaches 3 • Process Chain Configuration Systems • CAPP, I-ViP RP-Selector • Design process Chains from scratch

  19. Selection System Drawbacks • Difficulty in turning identifying model requirements and turning them into a specification • Reliance on making subjective judgements on model geometry & requirements • Existing Systems do not take into account external influences on design process

  20. Proposed Model

  21. Research Issues • Methodology for Correct RP/T Process Chain Selection • Structuring of Prototype Requirements • Understanding of the effect of external influences • Process Capability/Materials Database • Detailed Study into RP Capabilities • New Means of Structuring the Information • Embodiment of Methodology

  22. Research Strategy • Company Research Establish Attitudes/Practices within Prototyping Examine current uses of Prototypes • Evaluate Techniques such as QFD and Benefit Value Analysis for RP Specifiaction generation • Design and Evaluation of System

  23. Thank You for Your Attention

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